Process and device for fluidized bed spray granulation

In an apparatus for producing granules, having a fluidized bed of fluidizing gas and particles, means for spraying liquid starting material into the fluidized bed, means for discharging particles of at least a given size from below the bed and means for classifying the discharged particles and returning a relatively finer fraction of particles into the fluidized bed, the improvement wherein:

• a) the fluidized bed has a rectangular cross-section and includes a plurality of parallel zones along the length thereof such that the sum of the widths of the plurality of zones equals the length of the fluidized bed;
• b) the means for discharging comprises a full width underflow weir feeding a plurality of zig-zag classifiers, each classifier having downwardly extending zig-zag flow paths receptive of the discharged particles, the zig-zag classifiers each have a rectangular cross-section and are adjointly arranged side by side along the length of the fluidized bed and wherein the length of each zig-zag classifier is equal to the width of each zone;
• c) the means for classifying and returning comprises means for directing parallel countercurrent classifying air flows in the zig-zag flow paths, a plurality of separated return shafts downstream of the zig-zag classifiers for conveying the classifying air flows together with the relatively finer fraction of particles and each having means for directing the classifying air flows and particles into a corresponding single one of the plurality of separate parallel zones of the fluidized bed without cross mixing between the zones, such that for each zone the relatively small particles impinge at a relatively large distance from the return shafts and for each zone relatively large particles impinge at a relatively small distance from the return shafts, thereby passing said relatively large particles in each zone into the zig-zag classifiers more frequently than the relatively small particles;
• and
• d) wherein the means for spraying comprises means for spraying starting liquid separately into each of said zones of the fluidized bed comprising at least one spraying nozzle for each zone.